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Flexible Manufacturing
Version
3.0
1-0
Introduction
TS 1 Modular Conveyors
Liability:
In no event can the manufacturer accept warranty claims or liability claims for damages resulting
from improper use or misuse of the equipment or as a result of changes made to the equipment
other than those authorized by the manufacturer. The manufacturer will accept no claim in which
non-original spare parts have been used.
1-1
Introduction
Introduction
Workpiece Pallets
Transverse Conveyors
Curve Units
Lift-Transfer Units
Positioning Units
Stop Gates
Technical Data
1
2
3
4
5
1
6
7
8
9
10
11
1-2
Introduction
Table of Contents
Section 1: Introduction
1-4 - 1-7
1-8
System overview
Customer support services
1-9
1-10
Application photos
How to use this catalog
2-4
2-5
3-6
3-6
3-7
3-8 - 3-9
3-10
5-6 - 5-7
5-8 - 5-9
5-10
KU1/180 Curve
KU1/360 Curve
Accumulation Control, KU1/.... Curves
6-6 - 6-7
6-8 - 6-9
KE1/90-0 Curve
KE1/180-0 Curve
KU1/90 Curve
1-3
Introduction
8-4
8-5
10-3
10-3
10-4
Pallet loading
Pneumatic summary
Lift-transfer unit pneumatic diagrams
Positioning unit pneumatic diagrams
1-4
Introduction
SECTION 3
Drive Belts
SECTION 5
Curve Units
1-5
Introduction
SECTION 7
Lift-Position and
Positioning Units
SECTION 4
Transverse Conveyors
SECTION 8
Stop Gates
SECTION 3
Drives
SECTION 9
Proximity Switches
and Brackets
SECTION 3
Conveyor Section
Components
SECTION 2
Workpiece Pallets
SECTION 6
Lift-Transfer Units
SECTION 3
Leg Sets
SECTION 3
Return Units
16
Introduction
Parallel
Serpentine
Track
Roller
Return
Return
Curve
Return
Drive
Rectangular
A parallel configuration, while similar to a
rectangular system, uses tandem lift
transfer units or curve units to connect
the conveyor sections.
Transverse
Conveyor
Transverse
Conveyor
Drive
Drive
Return
Curve
Drive
Drive
Return
Lift-Transfer
Units
17
Introduction
Operation 1
Operation 2
Applications for TS 1
Station A
Station B
B
A
A
Station A
A
Station B
B
Automotive components
Ink-jet Cartridges
Hard drives
Small subassemblies
Electronics
Medical Devices
18
Introduction
Every assembly project has its challenges. But you dont have to meet them
alone. Bosch Rexroth offers the most
comprehensive program of customer
support available anywhere, from do-ityourself projects to turnkey installations.
Now that youve taken the first step by
requesting this catalog, well help you
with all the restfrom the initial quote and
installation, to servicing your line years
from now.
Application engineering
from experts, or via CAD
Whatever your application, our application engineers have probably worked on
it. Theyll carefully review your requirements cycle time, payload, floor space,
process flow and devise the best
conveyor layout to meet them.
If youd rather design the system yourself,
our FMSsoft program makes it easy. It
not only creates a 3-D layout based on
your parameters, but generates a bill of
materials to simplify ordering. This userfriendly program works on any CAD
system using AutoCAD Release 2000
or later.
Whichever you prefer, well respond
quickly with a detailed quotation and
answer any questions you may have.
And well work with you directly, or
through your local Bosch Rexroth
systems integrator, to schedule delivery
and installation when you need it.
19
Introduction
Application Photos
110
Introduction
1-800-322-6724
In Canada
1-905-335-5511
Transport Level
Nominal
Height
Transport Level:
= Workpiece pallet
= Nominal width
= Nominal length
= Workpiece pallet width
= Workpiece pallet length
= Lift transfer unit width
= Lift transfer unit length
WT
B
L
B WT
L WT
BQ
BL
150
L
Workpiece
Pallet
BQ
WT
BWT
BL
Lift Transfer
Unit
= Pallet Flow
LWT
T-Slot:
The longitudinal slot in the extruded
aluminum profiles of the conveyor
WT
L
LWT
B
T-Slot
Line Flow
Profile
Figure 1
T-Bolt
T-Nut
BWT
Transverse
Conveyor
2-1
Workpiece Pallets
WT1/K
Assembled Plastic
Workpiece Pallets
2-2 to 2-3
WT1/S
Assembled Steel Workpiece
Pallets
2-2 to 2-4
WT1/P
Assembled Aluminum
Workpiece Pallets with
Bushings
2-2 to 2-5
2-2
Workpiece Pallets
Exciter Block
Wear
Plates
Weight
kg
Max. Total
Weight kg.
Part Number
WT1/K
PA66
80 x 80 mm
120 x 120 mm
160 x 160 mm
0.075
0.135
0.225
1.5
2.2
3.0
WT1/S
80 x 80 mm
120 x 120 mm
160 x 160 mm
0.165
0.430
0.830
1.5
2.2
3.0
Aluminum frame,
80 x 80 mm
UHMW-PE Wear Strips, 120 x 120 mm
(4) Bushings
160 x 160 mm
0.205
0.440
0.760
1.5
2.2
3.0
Model
WT1/P
Pallet Material
2-3
Workpiece Pallets
F 0.2
B 42
WT1/K
4x 4.3
F 0.2
B 42
H
0.4
0.3
0.3
K
N/A
0.5
B1
16.5
5.5 0.1
12
B
0.1
2
32
8 H7 Measurement Contact
32
12
32
12
32
SW 10
12
10
50
130
90
79
159
10
5.5
80
120
NOTE: Dimensions are for reference only. Contact Rexroth for a detailed machining drawing.
16.5
119
160
24
Workpiece Pallets
B 42
B 28
Locating Groove, 2X
F 0.1
WT1/S
4x 4.3 0.05
F 0.1
B 42
E
F
G
H
K
0.25 19 0.20 0.20
0.25 39 0.25 0.25 N/A
0.25 59 0.30 0.30
B1
16.5
5.5 0.1
12
B
0.1
2
32
8 H7 Measurement Contact
32
12
32
12
32
SW 10
12
10
50
130
90
79
159
80
16.5
5.5
10
119
120
NOTE: Dimensions are for reference only. Contact Rexroth for a detailed machining drawing.
160
25
Workpiece Pallets
5.5
5.5
10
16.5
Pallet
Size (b)
A
80
80 x 80
WT1/P 120 x 120 120
160 x 160 160
Measurement
Contact 8h7
4x12
5.5
0.03
5.5
B
38
78
118
C
19
39
59
4x 6 F7
E 0.03
F
G
Pallet
Size (b)
D
50
80 x 80
WT1/P 120 x 120 90
160 x 160 130
NOTE: Dimensions are for reference only. Contact Rexroth for a detailed machining drawing.
E
38
78
118
F
32
32
32
G
12
12
12
3-0
3
Belt Drive components in this section can be configured into any
of the basic line layouts below.
Drive
Return
Return
Drive
Drive
Return
In-Line
Parallel
Return
Drive
Drive
Return
Rectangular
UM1
Belt Returns
3-1
AS1
Belt Drives
3-2 to 3-3
ST1
Conveyor Sections
and Cross Links 3-4
SP1
Connection Links and
Conveyor Section Profile
3-5
Foundation Brackets
3-10
3-1
Your
Choices are:
B+25
AS 1
UM 1
Part Number
3842 521 260
Part Number
3842 999 760
Your selection:
32
80
Model AS1
Outboard Mounted
Motor position
Outboard Mounted
Motor orientation
180
Transport direction
Transport direction
270
90
0
AS1
Drive Unit
3842 999 759
Your
choices are:
Your
selection:
__________mm
Nominal speed*
9, 12, 15, 18
________m/min.
Motor voltage/frequency
See Table 3 - 1
______V ____Hz
Motor Orientation
______________
Motor Position
L, R
______________
* Full load conveyor speeds vary depending on motor frequency. See Table 3-1
To omit motor, specify 000V 00Hz.
33
s
ter
me
.0
2
kg
=1
.0
gth = 80 F
en
d
L
a
F
x.
Lo
Ma Max. F
=
=
=
=
=
=
130
B+25
260
200
B +1
66
50
123
310
121
177
34
QV 1 Cross Connector
5
0
0
Conveyor Section
Le
ng
t
Model ST1
3
The 8 mm T-slot in each side and the
bottom of the aluminum profile allows
conveyor modules or peripheral devices
to be attached using T-bolts or T-nuts,
eliminating the need for special machining.
Part Number
* To order conveyor sections 200-6000 mm long, please specify desired length at the end of the
part number. For example, to order a standard 2000 mm belt conveyor section, your part
number should look like this: 3842 999 779/2000.
Cross Connectors
0
3
b-
31.5
FP 1
Model QV1
Cross connectors must be used to
maintain conveyor section width and
alignment. QV1 cross connectors should
be used every 500 mm as well as over
each leg set. Order cross connectors
according to line width. Includes
connection hardware.
Material:
Plastic PA6
22
.5
Part Number
Cross Connector, B = 80
35
Connection Link
Connection links join conveyor sections
end-to-end. Two connection links are
required to join a conveyor section, one
on each rail. They are made of galvanized
steel for strength and come with all
required fastening hardware
50
6
40
16
Material:
Zinc chromated steel
M6
10Nm
Part Number
22.5
16
Model SP1
SP1 conveyor section profile is a natural
color anodized aluminum extrusion. The 8
mm T-slot on both sides and the bottom
allows the mounting of conveyor modules
or peripheral devices using T-bolts or Tnuts eliminating the need for additional
machining.
55
8
22.5
Part Number
* To order conveyor section profiles 100-6000 mm long, please specify desired length in 1 mm
increments at end of part number. For example, to order a 2051 mm conveyor section profile,
your part number should look like this: 3842 992 934/2051.
36
Model FP1
11
Material:
Black, electrically conductive
polyethylene
Part Number
* To order belt guide profiles 50-2000 mm long, please specify desired length in 1 mm increments
at end of part number. For example, to order a 1027 mm belt guide profile, your part number
should look like this: 3842 992 943/1027.
Transport Belt
15
1.75
Model GT1
Electrically conductive, GT1 belt is used
to transport the workpiece pallets. In
normal operation, the belts run continuously, carrying the pallets on their
surface. The low coefficient of friction
between the belt and pallet allows pallets
to be stopped and accumulate on the
conveyor while the belts continue to run.
Transport belt is available in 50 meter
rolls or pre-cut to any desired length in 1
mm increments up to 50 meters.
When installing or replacing belts, they
must be tensioned and welded to create
a continuous loop in each conveyor
section. Tensioning ensures proper
positive contact with the drive pulleys.
Use the belt welding kit on page 3-7 to
tension, grind and weld the belt ends.
Part Number
* To order belt in lengths up to 50 meters, please indicate desired quantity in .001 meter
increments after the part number. For example, to order 43.485 meters of belt, your part
number should look like this: 3842 521 166 Qty. = 43.485
[mm]
37
Tensioning
Device
3
To cut welding time in half, a second
heating press is recommended for
welding two adjacent belts at the same
time.
NOTE: This kit is for flat belts only and
not intended for use on toothed or round
transport belts.
Belt Grinder
Belt Heating Press, 110VAC, 60Hz
Part Number
38
Leg Sets
Model SZ1/L, SZ1
SZ1
SZ1/L
Your
Choices are:
Width (B)
Height (H)
Part Number
3842 999 702
Your selection:
_____________ mm
_____________ mm
Your
Choices are:
Width, (B)
60, 135
H = < 200 > 1200
Part Number
3842 999 703
Your selection:
_____________ mm
_____________ mm
_____________ mm
39
62.5
SZ 1/L
B SZ
45
B SZ = B WT+15
62.5
SZ 1
45
B SZ = 2 x(B WT+15)+a
Foundation Brackets
43
175.5
SW13
.5
SW13
85
8 mm Anchor Bolt
76
8 (5/16")
73
Cover Cap
8 (5/16")
Part Number
Return End
2 m typ.
2 m typ.
Foundation Bracket
Drive End
41
Transverse Conveyors
BS1
Transverse Conveyor
4-2 to 4-3
BS1/T
Transverse Conveyor
4-4 to 4-5
BS1/M
Mid-mount Transverse
Conveyor
4-6 to 4-7
42
Transverse Conveyors
Transverse Conveyor
30
Model BS1
Outboard Mounted
Motor Orientation
Motor Position
L
180
Primary Pallet
Flow
Pallet
Flow
270
0
Your
Choices are:
Part Number
3842 999 898
Your selection:
Width (B)
_______________ mm
Belt Type
Non-Antistatic (N)
Antistatic
(A)
__________________
Length (L)
250 to 5000
(in 5 mm increments)
_______________ mm
6, 9, 12, 15, 18
_____________ m/min
Motor Voltage/frequency
_______ V _______Hz
Motor Orientation
Motor Position
0, 180, 270
L, M**, R
__________________
__________________
* Full load conveyor speeds vary depending on motor frequency. See Table 4-1
** Mid-mount available on 160 mm wide modules with 0 motor orientation only.
270 motor orientation only available when Length (L) > 400mm.
43
Transverse Conveyors
Actual Speed
50 Hz
6.9
8.2
11.0
13.7
16.4
60 Hz
6.7
8.3
13.3
16.6
N/A
Note: Electrical Data for reference only. Refer to motor data plate for actual ratings.
Table 4-1
B + 28
B+1
B 45
27
B + 125
B + 28
110
285
77.3
72
B+1
44
Transverse Conveyors
Transverse Conveyor
30
Model BS1/T
Outboard Mounted
Motor Orientation
Motor Position
L
180
Primary Pallet
Flow
Pallet
Flow
270
0
Your
Choices are:
Part Number
3842 999 899
Your selection:
Width (B)
_______________ mm
Belt Type
Non-Antistatic (N)
Antistatic
(A)
__________________
Length (L)
320 to 5000
(in 5 mm increments)
_______________ mm
6, 9, 12, 15, 18
_____________ m/min
Motor Voltage/frequency
_______ V _______Hz
Motor Orientation
Motor Position
0, 180, 270
L, M**, R
__________________
__________________
* Full load conveyor speeds vary depending on motor frequency. See Table 4-2
** Mid-mount available on 160 mm wide modules with 0 motor orientation only.
g270 motor orientation only available when Length (L) > 400 mm
45
Transverse Conveyors
Actual Speed
50 Hz
6.9
8.2
11.0
13.7
16.4
60 Hz
6.7
8.3
13.3
16.6
N/A
HP
.125
.125
.125
.125
.125
Note: Electrical Data for reference only. Refer to motor data plate for actual ratings.
Table 4-2
B + 125
B 40
B + 28
110
L
285
72
B+1
4-6
Transverse Conveyors
30
Model BS1/M
Outboard Mounted
Motor Orientation
180
Primary Pallet
Flow
Motor Position
Pallet
Flow
90
270
Your
Choices are:
80, 120, 160
280 to 5000
(in 5 mm increments)
80 to 2450
(in 5 mm increments)
6, 9, 12, 15, 18
See Table 4-3
0, 90, 180, 270
L, M**, R
Non-Antistatic (N)
Antistatic
(A)
Part Number
3842 999 900
Your selection:
_______________ mm
_______________ mm
_______________ mm
_____________ m/min
_______ V _______Hz
__________________
__________________
__________________
* Full load conveyor speeds vary depending on motor frequency. See Table 4-3
** Mid-mount available on 160 mm wide modules with 0 motor orientation only.
g270 motor orientation only available when Length (L) > 400 mm
4-7
Transverse Conveyors
Nom.
M/min
6
9
12
15
18
50 Hz
6.9
8.2
11.0
13.7
16.4
60 Hz
6.7
8.3
13.3
16.6
N/A
Note: Electrical Data for reference only. Refer to motor data plate for actual ratings.
Table 4-3
B+1
B 45
B + 28
27
L2
110
L1
L
285
72
77.3
B+1
5-0
Curve Units
The KE1 curves use a round polyurethane belt to pull pallets through the
curve and can transfer up to 5 kg. 180
units are available for parallel conveyor
line gaps of 60 and 135 mm. Accumulation must be avoided through the curve
on all KE1 modules.
KE1/0-90
90 Curve
5-1
KU1/90
90 Curve
5-4
The KU1 curves use a flat polyurethane turntable to pull pallets through
the curve and can transfer up to 30
kg. 360 units combine the functionality of two 180 curve sections and
two transverse conveyors all powered
from one motor. KU1 curve units are
capable of passing multiple pallets
through the curve as long as the load
carrying capacity of the unit is not
exceeded.
KE1/0-180
180 Curve
5-2
KU1/180
180 Curve
5-6
KU1/2X180
2X180 Curve
5-8
51
Curve Units
90 Curve
Model KE1/0-90
Your selection:
___________________
___________________
L, R
Direction of Rotation
A
Mounting Type
Part Number
3842 999 764
Your
Choices are:
AS1
AS1
BS1/T
UM1 BS1
Pallet Flow
Pallet Flow
___________________
(specify A, B, C, or D)
BS1
BS1/T
or
BS1/T
Pallet Flow
UM1
Pallet Flow
90
Left Rotation
b +38
2
b +55
91
b+1
b +38
2
b +55
91
BS/UM
Right Rotation
90
75
52
Curve Units
180 Curve
Model KE1/0-180
Your
Choices are:
________________ mm
60, 135
________________ mm
Direction of Rotation
L, R
___________________
A
AS1
Mounting Type
AS1
Your selection:
B
BS1/T
UM1 BS1
Pallet Flow
Pallet Flow
___________________
(specify A, B, C, or D)
BS1
BS1/T
or
BS1/T
Pallet Flow
UM1
Pallet Flow
53
Curve Units
90
75
90
75
BS / UM
b + 55
91
BS / UM
(b + 1) +15 + a
2 x (b + 1) + a + 50
(b + 1) +15 + a
a+15
Left Rotation
b+1
Left Rotation
2 x (b + 1) + a + 50
a+15
Right Rotation
b+1
Right Rotation
b+1
91
b+1
b + 55
54
Curve Units
90 Curve
30
Model KU1/90
KU1/90
L1 = 0mm, L2 = 2000mm
KU1/90
L1 = 0mm, L2 = 0mm
_______________ mm
_______________ mm
6, 9, 12, 15, 18
_____________ m/min
_______ V _______Hz
L, R
Direction of Rotation
Belt Type
_______________ mm
0 or 150 - 5000
(in 5 mm increments)
0 or 150 - 5000
(in 5 mm increments)
Your selection:
Motor Voltage/frequency
The KU1/90 is shipped partially
assembled. The curve, L1 conveyor
section, and L2 conveyor section are
shipped as separate units.
Part Number
3842 999 986
Your
Choices are:
I = Inboard
A = Outboard
Non-Antistatic (N)
Antistatic
(A)
__________________
__________________
__________________
* Full load conveyor speeds vary depending on motor frequency. See table 5-1.
** See Dimensional data for KU1/90 (Page 5-5).
Non-antistatic (N) belt is available on L1 or L2 only when length is 150mm or greater.
Part Number
3842 528 855
3842 530 095
R980 024 552
R980 024 552
55
Curve Units
=
=
=
=
=
Actual Speed
50 Hz
6.9
8.2
11.0
13.7
16.4
60 Hz
6.7
8.3
13.3
16.6
N/A
Note: Electrical Data for reference only. Refer to motor data plate for actual ratings.
Table 5-1
L1
I = Inboard
L2
74
L = Left
Rotation
110
14
20
R = Right
Rotation
A = Outboard
85
92
300
128
35
B (mm)
80
120
160
E
162
202
240
F
165
203
243
G
372
435
492
56
Curve Units
180 Curve
30
Model KU1/180
KU1/180
L1 = 2000mm, L2 = 1000mm
KU1/180
L1 = 0mm, L2 = 0mm
_______________ mm
_______________ mm
_______________ mm
_____________ m/min
_______ V _______Hz
__________________
A = Outboard
A (outboard)
__________________
Non-Antistatic (N)
Antistatic
(A)
__________________
Your selection:
6, 9, 12, 15, 18
L, R
Direction of Rotation
The KU1/180 is shipped partially
assembled. The curve, L1 conveyor
section, and L2 conveyor section are
shipped as separate units.
Part Number
3842 999 987
Your
Choices are:
* Full load conveyor speeds vary depending on motor frequency. See table 5-2.
** Motor can only be mounted in the outboard position (see Dimensional data pg. 5-7).
Non-antistatic (N) belt is available on L1 or L2 only when length is 150mm or greater.
Part Number
3842 528 855
3842 530 095
R980 024 552
R980 024 552
57
Curve Units
=
=
=
=
=
Actual Speed
50 Hz
6.9
8.2
11.0
13.7
16.4
60 Hz
6.7
8.3
13.3
16.6
N/A
Note: Electrical Data for reference only. Refer to motor data plate for actual ratings.
Table 5-2
5
Dimensional data for KU1/180
L1
L = Left
Rotation
L2
135
110
14
R = Right
Rotation
85
92
300
A = Outboard
128
35
B (mm)
80
120
160
F
165
203
243
G
422
505
580
58
Curve Units
2x180 Curve
24-30
Model KU1/2x180
Your
Choices are:
80, 120, 160
150 - 5000
(in 5 mm increments)
1, 2
Part Number
3842 999 988
Your selection:
_______________ mm
_______________ mm
__________________
6, 9, 12, 15, 18
_____________ m/min
_______ V _______Hz
L, R
__________________
A = Outboard
A (outboard)
__________________
Non-Antistatic (N)
Antistatic
(A)
__________________
* Full load conveyor speeds vary depending on motor frequency. See table 5-3.
** Motor can only be mounted in outboard position. See Dimensional data (pg. 5-9).
59
Curve Units
=
=
=
=
=
=
5
Dimensional data for KU1/2x180
135
L = Left
Rotation
L1
B (mm)
80
120
160
F
165
203
243
G
422
505
580
R = Right
Rotation
A = Outboard
510
Curve Units
bwt +10
VE 1
W I /M
Figure 5-1
WI 1/M
with Pneumatic
Cylinder Switch
VE 1
Figure 5-2
61
HQ1/U
Lift-Transfer Units
6-2 to 6-3
EQ1/TR
Tandem Lift-Transfer Units
6-4 to 6-5
EQ1/T
Tandem Lift-Transverse
Conveyor 6-6 to 6-7
EQ1/TE
Tandem Lift-Transverse
Conveyor 6-6 to 6-7
62
Lift-Transfer Unit
Model HQ1/U
Your
Choices are:
80 x 80 mm
120 x 120 mm
160 x 160 mm
Part Number
3842 998 010
Your selection:
_______________ mm
6, 9, 12, 15, 18
_____________ m/min
Motor Voltage/frequency
_______ V _______Hz
* Full load conveyor speeds vary depending on motor frequency. See Table 6-1
Each LTU is equipped with steel side
guides to guide the pallets during
transfer. Each guide may be raised up
slightly to act as a pallet stop when the
transfer is in the centered, or rest,
position. Optional cushioned transfer
stops (see page 8-4) may be mounted to
the side guides to provide adjustable
cushioned stops instead of hard stops on
the transfer.
63
BQ
BQ + 55
BL - 32
+4.4=Raised Position
=Transport Surface
2.2 Center, Rest Position
8.6 Pass-through Position
BL +15
BQ +55
BQ
377
66
BL
105
64
Model EQ1/TR
Your
Choices are:
80 x 80 mm
120 x 120 mm
160 x 160 mm
Part Number
3842 998 012
Your selection:
_______________ mm
60, or 135 mm
_______________ mm
6, 9, 12, 15, 18
_____________ m/min
Motor Voltage/frequency
_______ V _______Hz
* Full load conveyor speeds vary depending on motor frequency. See Table 6-2
65
B Q+59
BQ
B Q+1
B L +A+15
+4.4=Raised Position
B L +1 5
=Transport Surface
2.2 Center, Rest Position
A
354
16 0
62.5
BL
B L -30
66
30
Model EQ1/T
Outboard Mounted
Motor Orientation
180
Primary Pallet
Flow
Motor Position
Pallet
Flow
270
Your
Choices are:
80 x 80
120 x 120
160 x 160
Part Number
3842 998 013
Your selection:
_______________ mm
Non-Antistatic (N)
Antistatic
(A)
320 to 5000
(in 5 mm increments)
__________________
6, 9, 12, 15, 18
_____________ m/min
Motor Voltage/frequency
_______ V _______Hz
Motor Orientation
0, 180, 270
__________________
L, M**, R
__________________
Belt Type
Length (L)
Motor Position
_______________ mm
* Full load conveyor speeds vary depending on motor frequency. See Table 6-3
** Mid-mount only available on 160 mm wide modules
67
BQ+55
BL+15
110
BQ
BL+15
+4.4=Raised Position
=Transport Surface
2.2 Center, Rest Position
8.6 Pass-through Position
BL
105
295
105
66
BL
68
Lift-Transverse Conveyor
30
Model EQ1/TE
Outboard Mounted
Motor Orientation
180
Primary Pallet
Flow
L
Pallet
Flow
270
Part Number
8981 999 259
Your
Choices are:
80 x 80
120 x 120
160 x 160
Drive end
Return end
Your selection:
_______________ mm
(D)
(R)
Non-Antistatic (N)
Antistatic
(A)
320 to 4900
(in 5 mm increments)
__________________
__________________
_______________ mm
6, 9, 12, 15, 18
_____________ m/min
Motor Voltage/frequency
_______ V _______Hz
Motor Orientation
0, 180, 270
__________________
L, M**, R
__________________
Motor Position
* Full load conveyor speeds vary depending on motor frequency. See Table 6-4
** Mid-mount only available on 160 mm wide modules
69
BL+15
BQ+55
BQ
110
+4.4=Raised Position
=Transport Surface
2.2 Center, Rest Position
BL
105
295
105
66
7-0
Positioning Units
10
80
PE1/P
Positioning Unit
7-1
HP1
Lift-Position Unit
7-2 to 7-3
7-1
Positioning Units
Positioning Unit
10
Model PE1/P
Your
choices are:
The positioning units mount directly to the Tslots in the bottom of the conveyor profile or
to the table top of an automatic workstation.
Your
choices are:
= 10 kg
= 100 N
Part Number
3842 998 101
Your selection:
Part Number
3842 998 102
Your selection:
B=...
80
120
160
Permitted Turning = 10 Nm
Moment
Stroke
= 6.5 mm
Cylinder Diameter = 25 mm
Air pressure
= 4-8 bar
Air fittings
= 4 mm
Tap M6
End View
B+87
46.5
99.5
50
120
119.5
53
107. 4 5
1.05
52
45
15
119.5
Top View
23.5
1.5
B +15
B +44.5
14.5
WT 1/K: S = 0.8 mm
WT 1/S: S = 0.8 mm
WT 1/P: S = 1.5 mm
*Dimensions are for reference only. Contact Rexroth for a detailed machining drawing.
100 0.0.025
72
Positioning Units
Lift-Position Unit
80
Model HP1
Part Number
3842 999 805
Your
Choices are:
Your selection:
__________________
3842 524 092
50
0 50
135
73
Positioning Units
=
=
=
=
=
=
=
=
=
80 kg
0.025 mm both x and y axis
400 N
15 Nm
4-8 bar
8 mm fixed
0-50 mm adjustable
50 mm
4 mm
L1
128
B 42
R7
.5
15
B + 13
B 32
B 42
2X 6 (H7)
D
4X M6
A
80
120
160
Stroke
(8 to 50)
200
60.5
62.5
L2
A
141
141
181
125
*Dimensions are for reference only. Contact Rexroth for a detailed machining drawing.
66
B
90
130
170
C
31
50
90
D
9.5
10
10
E
50
70
110
8-0
Stop gates
8
VE1
Standard Stop Gate
Page 8-1
AL1
Stop Rail
Page 8-5
VE1/D, VE1/DA1B
Cushioned Stop Gates
Page 8-2 to 8-3
WI1/M
Rocker Stop
Page 8-6
VE1/DA
Transfer Stop
Page 8-4
81
Stop Gates
Stop Gate
Model VE1
Description
Part Number
Stop Gate
Description
VE1 Queue Load (kg)
12
15
18
80
60
40
40
A
Leading
Edge
4-6 Bar
B
Trailing
Edge
82
Stop gates
Part Number
Description
VE1/D Queue Load (kg)
12
15
18
10
10
10
8
Dimensional data for VE1/D
Stroke
7
35
57
65
40
38.5
8.0 0.1
16
30
63
83
Stop Gates
Product Bulletin
Part Number
8
Dimensional data for VE1/DA1B
54
4.5
25
WT 1/P
31
4.2
7. 5
33.5
26
33
34
27
M5
33
84
Stop gates
Description
Part Number
Transfer Damper
Description
VE1S/DA Queue Load (kg)
12
15
18
10
62
7
VE1/DA
WT 1
20
33
EQ 1/TR
7 Stroke
AL1
42
22
33
4.5
M5
M4
25
18
73
85
Stop Gates
Stop Rail
Model AL1
Part Number
Stop Rail
8
8
12
70
86
Stop gates
44
41.5
19
(91)
10.5
16.5
37
35.5
14
40
22
29
bwt +10
VE 1
WI/M
Part Number
91
SH1/U
Vertical sensing bracket
9-2
SH1/S
Horizontal sensing bracket
9-3
SH1/M
Horizontal sensing bracket
9-4
Proximity Switches
9-5
92
Part Number
53
39
6.5
13
13
93
Description
Part Number
20
13
35
41
Exciter Block
See Page 2-2
40
84
72
14
94
Part Number
14
18.5
25.5
18.5
11
40
KU1
40
AL1
ST 1
ST 1
7
6.5
19
14
14.7
6.5
14.7
19
WT 1
SH 1/M
WT 1
14
SH 1/M
14
25.5
95
Proximity Switches
A.
C.
B.
50 m
90 Quick
Disconnect Plug
with 5m of 3-conductor
cable
Sensing
Application
Sensing
Range
Part Number
8981 021 153
8981 018 805
8981 018 806
10-0
Technical Data
Conveyor width
Conveyor width is determined by the size
of the workpiece pallet. Maximum payload
depends on the length of the load-bearing
edge (LWT or BWT) of the workpiece pallet.
Maximum permissible loading for the load
bearing edge is shown in Figure 10-1
Maximum permissible workpiece pallet
payload (includes pallet, fixturing,
workpiece and coding system) depends
on the supported length of the pallet as
shown in Figure 10-2.
Workpiece Pallet
load-bearing edge Maximum
Load in kg*
LWT or BWT
80
1.5
120
160
2.2
3.0
BW
LW
* Maximum load is the combined weight of all pallet components, fixture, and parts.
Figure 10-1
Workpiece
pallet
Transportation speed
Preferred speed is 12 m/min on conveyor
sections and transfers. Performance data
for individual modules is based on these
speeds, although different speeds can be
selected. Transportation speed is
selected based on system cycle time,
time required by the workpiece pallet to
enter a workstation, total weight of the
pallet, and stability of the workpiece on
the pallet.
10
Supported length
Conveyor section
Conveying media
Figure 10-2
Conveying direction
Workpiece pallets should be conveyed
toward a drive unit. Reversible operation
is only possible when explicitly stated.
Transportation direction
MAXIMUM LOAD
F
Figure 10-3
101
Technical Data
Application
CE identification, responsibility
Materials used
Planning
Transfer system planning (the
combination of components into a
modular system), set-up, initial start-up
and maintenance should only be done by
trained personnel. Rexroth offers training
courses for this purpose.
Note
Examples
Installation references, pneumatic
switching plans and typical function
processes are described in the catalogs
and assembly instructions. These must
be followed when setting up and
commissioning the system.
Ambient conditions
Environmental conditions climatic
The transfer systems have been
designed for stationary use in a location
that is protected from the elements.
Operating temperature
+5 to +40C
-5 to +60C with 20% less load
Storage temperature
-25C to +70C
Relative humidity
5 to 85%, non-condensing
Air pressure
>84 kPa in accordance with installation
altitude <1400m above sea level.
Load values are reduced by 15% when
the system is set up at a location that is
over 1,400m above sea level.
Environmental conditions biological
Avoid molds, fungi, rodents, and other
vermin.
Environmental conditions chemical
Do not set up near industrial systems
with chemical emissions.
Environmental conditions physical
Do not set up near sandy or dusty
sources. Do not set up in areas that are
regularly jarred by high forces caused by
e.g. presses, heavy machinery, etc.
Media Resistant
Resistant to many common media used
in production such as water, mineral oil,
grease, and detergents. Contact your
Rexroth representative if you have any
doubts about resistance to specific
chemicals, e.g. test oil, doped oils,
aggressive detergents, solvents, or
brake fluid. Avoid long-term contact with
acidic or basic reacting materials.
Contamination
Wear may increase dramatically if the
system is contaminated due to
environmental factors, particularly with
abrasive media such as sand and
silicates, but also due to processes
running on the transfer system (e.g.
welding beads, pumice dust, glass
shards, shavings, or lost parts). In
such cases, maintenance intervals must
be substantially shorted.
10
102
Technical Data
Functional reliability
Maintenance
Load specifications
Wear
With individual components, wear is
caused by the basic principle and cannot
be avoided. Constructive measures and
selection of the proper material will help
functional reliability last for the entire
service life. However, wear depends on
the operating, maintenance, and ambient
conditions of the system and the
location (resistance, contamination).
Environmental sustainability,
recycling
The materials used are environmentally
sustainable and may be recycled or
reused (if need be, by converting or
replacing components). Recyclability is
ensured by the selection of material and
the possibility to take the components
apart.
10
103
Technical Data
Pneumatic Summary
NOTE: Non-oiled DRY air, 58-116 PSI (4-8 bar) connected through 4 mm push-lock plastic
tubing is required on all TS 1 pneumatic components.
Module
Bore
(mm)
HQ1/U
25
EQ1/TR
25
EQ1/T
EQ1/TE
Stroke
(mm)
Volume (cc)
per stroke
Tube Size
10
4.9
4mm
M5
10
9.8
4mm
M5
25
10
9.8
4mm
M5
25
10
4.9
4mm
M5
PE1/
25
HP1
50
58
VE1
DA1
4mm
M5
4mm
M5
3.9
4mm
M5
4.8
4mm
M5
2.2
4mm
M5
7
7
20
Module
2.9
113.9
25
16
VE1/D
Port
Port
Flow rate
barbed hose
connector
40l/min
Not
Included
10
Not
Included
4 mm
4 mm
1
2
1
5
Not
Included
Not
Included
4 mm
4 mm
104
Technical Data
2
4 mm
Not
Included
Pneumatic diagram,
Pneumatic Cylinder Switch
VE 1
10
P
4 mm
4 mm
2
R
CE Declaration
CE Declarations are not shipped with modules. When you order CE compliant
modules, please contact our applications engineering department for the latest
revision level of the manufacturer's CE declaration if required for your records.
105
Technical Data
Conversion Factors
Multiply
by
to get:
Linear
millimeters (mm)
inches
kilometers (km)
miles
millimeters 2 (mm 2 )
inches 2
centimeters 3 (cm3 )
inches 3
1 Liter
meter/second 2 (m/s 2)
inch/second 2
meter/second (m/s)
feet/second
kilogram (kg)
pounds
kilograms-f (kgf)
Newtons (N)
pounds-f
Newtons (N)
bar
PSI
Newton-Meters (Nm)
pound-inches
centimeters 4 (cm 4)
inches 4
kilowatts (Kw)
horsepower (HP)
Joules (J)
foot/pounds (ft/lbs)
0.03937
25.4
0.6214
1.6093
0.00155
645.16
0.06102
16.387
61.025
39.37
0.0254
3.281
0.3048
2.2046
0.4536
9.807
0.10194
4.448
0.2248
14.5
0.069
8.851
0.11298
0.02403
41.623
1.34
0.746
0.7376
1.3558
inches
millimeters (mm)
miles
kilometers (km)
inches 2
millimeters 2 (mm 2)
inches 3
centimeters 3 (cm 3)
inches 3
Area
Volume
Acceleration
Velocity
Mass
Force
Pressure
Torque
Moment of Inertia
Power
Energy
Tap
Drill Size
M4
M4 x .7
3.3 mm
M5
M5 x .8
4.2 mm
M6
M6 x 1
5.0 mm
M8
M8 x 1.25
6.8 mm
M12
M12 x 1.75
10.2 mm
M16
M16 x 2
14.0 mm
inch/second 2
meter/second 2 (m/s 2)
feet/second
meter/second (m/s)
pounds
kilogram (kg)
Newtons (N)
kilograms-f (kgf)
Newtons (N)
pounds-f
PSI
bar
pound-inches
Newton-Meters (Nm)
inches 4
centimeters 4 (cm 4)
horsepower (HP)
kilowatts (Kw)
foot/pounds (ft/lbs)
Joules (J)
Temperature
Degrees Celsius
Degrees Fahrenheit
5 x (degrees F - 32)
9
(9 x degrees C) + 32
5
10
110
Part Number
11
Page
Part Number
Page
Part Number
Page
9-4
2-2
4-6
9-4
2-2
5-4
9-2
2-2
5-6
9-3
8-6
5-8
8-5
8-6
3-7
3-5
2-2
9-4
3-6
2-2
9-4
3-4
8-3
9-4
3-4
9-2
6-8
3-4
3-5
3-7
3-6
3-6
8-1
6-2
8-2
6-4
8-4
6-6
3-10
7-1
3-10
7-1
7-2
3-8
3-10
3-8
2-2
3-2
2-2
3-1
2-2
5-1
2-2
5-2
2-2
3-4
2-2
7-2
3-10
4-2
3-5
4-4
TS4plus is
widely used in
the appliance
and automotive
industries
because of its
ability to handle
large and heavy
products like automotive drivetrain
components, ranges or even refrigerators. In precision assembly, TS4plus can
achieve a repeatability factor of 0.125
mm. The power and free roller design
allows accumulation with minimum
queuing pressure.
Workpiece Pallet Size Range:
443 x 443 mm to 1243 x 1243 mm in
200 mm increments
Workpiece Pallet Load Capacity:
Up to 250 kg (550 lbs)
Transport Media:
Roller Chain
Transport Rate:
6, 9, 12 or 15 m/min
VarioFlow is a
single strand
conveyor system
designed for the
specific needs of
the packaging,
material handling
and assembly industries in two system
widths, 65mm and 90mm. Extremely
stable chain design allows VarioFlow to
achieve chain tensile forces (pulling
strength) of 1250 N in both widths.
Transport speeds include nine fixed and
two variable speed drives.
VarioFlow: Model VF65
Product Width: 15-175 mm
Maximum Product Weight: 10kg.
VarioFlow: Model VF90
Product Width: 35-200 mm
Maximum Product Weight: 20kg.
Transport Rate:
Fixed or variable up to 60 m/min.